AIR COOLED CONFIGURED SCREW CHILLERS - HIGH-EFFICIENCY SERIES

Blue Star, India’s largest central air conditioning company has been providing
expert cooling solutions for over seven decades now. As a leader in the industry, it
manufactures a wide range of scroll, screw and centrifugal chillers, providing cool
comfort in hospitals, airports, green buildings, hotels, malls etc.

Based on its continued thrust for research and product development, Blue Star
launches a new state-of-the-art configured series of AHRI certified air cooled
screw chillers. These chillers provide application versatility, energy efficiency, low
sound levels, precision control, reliability, ease of installation and operational cost
effectiveness. The chillers are designed to deliver high performance and a host of
other benefits.
MADE IN INDIA - MADE FOR INDIA
The new configured series screw chiller is manufactured at Blue Star’s ISO 9001 certified
factory. Blue Star has state-of-the-art chiller testing facility certified by the Air Conditioning,
Heating and Refrigeration Institute (AHRI). The chillers are designed to deliver better
efficiencies even at high ambient temperature prevalent in India.
WIDE CAPACITY RANGE
The chillers are offered in a wide range of capacities from 100TR to 400TR with single/twin
compressors. The performance is validated by AHRI. The condenser surface area and number
of passes across the cooler can be modified to suit project capacity, pressure drop and
efficiency. The chillers are designed to operate at 415V, 50Hz, on a 3-phase power supply.
Single Compressor Range:

100TR to 200TR

Double Compressor Range:

130TR to 400TR
PROJECT SPECIFIC CHILLER DESIGN
The new Blue Star configured high-efficiency series aircooled screw chiller can be
selected based on project specific requirement. Unlike the conventional chillers,
Blue Star’s latest screw chillers are not limited to a few models. The configured
series has an exhaustive range of coolers, condensers and compressors which offers
flexibility to select chillers based on varied needs of customers like:

Capacity Noise levels

Energy efficiency Flow rates

Ambient temperature Dimensions

Pressure drops

Cooler

Compressor

Condenser
HIGH ENERGY EFFICIENCY
The new Blue Star configured series screw chiller is designed for high
performance, both at full load and part load. This series comes with:
High-efficiency semi-hermetic twin screw compressors.

REFRIGERANT
GAS OUT

REFRIGERANT
LIQUID IN

FLOODED EVAPORATOR

Flooded evaporator design that aids in:

Reducing the temperature gradient between the refrigerant and water

Higher evaporating temperature

Negligible superheat

All the above resulting in higher efficiency

Electronic expansion device to precisely control the refrigerant flow

VFD drive option for condenser fan motor, providing varied benefits like:

Compatibility with low ambient temperature (up to 0⁰C) applications

Optimised noise levels

The new high-efficiency series offers exceptional COP and IPLV values exceeding the
national and international energy norms like ECBC and ASHRAE 90.1.

ECBC Values
Chiller Type Capacity Minimum Efficiency

COP IPLV
Air Cooled Screw < 150TR 2.9 3.16
Air Cooled Screw > 150TR 3.05 3.32

ASHRAE 90.1 Minimum Efficiency

Capacity Range Path A (kW/TR) Path B (kW/TR)

COP IPLV COP IPLV

< 150TR 2.96 4.02 2.84 4.63
> 150TR 2.96 4.1 2.84 4.72
CHILLERS DESIGNED FOR GREEN BUILDING
Green buildings are environmentally sustainable and are designed, constructed
and operated to minimise any adverse impact on the environment.

An air conditioning system consumes about 40% of the annual building energy.
Therefore, selection of the right air conditioning system is one of the main
aspects to consider while designing a green building.

The choice of Heating, Ventilation and Air Conditioning (HVAC) products can
have a significant impact on LEED certification as it can influence 40% of the
available points.

100 possible LEED points Overview of LEED for new construction and major renovations

80-100 points Regional priority

(4 points)
Platinum Sustainable site
(25 points) Energy & Atmosphere
60-79 points
(35 points)
HVAC contribution
Gold 26 of 35 points
50-59 points Innovation &
Design process
Silver (6 points)
40-49 points
Indoor enviromental
Certified Water efficiency quality (15 points)
(10 points) HVAC contribution 6
Material & Resources
of 15 points
(14 points)

EA prerequisite 2 : Minimum Energy Performance

The chillers shall meet the energy efficiency requirements of ASHRAE 90.1.

EA prerequisite 3 : Fundamental Refrigerant Management

The chillers shall not use Chlorofluorocarbon (CFC) refrigerants.

EA credit 4 : Enhanced Refrigerant Management

LEED awards the systems that minimise the Ozone Depletion Potential
(ODP) and Global Warming Potential (GWP).

EA credit 1 : Optimised Energy Performance

One section of this credit requires the reduction in energy consumption

exceeding the ASHRAE 90.1 minimum efficiency beyond EA prerequisite 2.

The high-efficiency series of chillers shall meet all the above criteria.
HIGH RELIABILITY
The chillers are equipped with twin rotor screw compressors having advanced 5-6
patented profiles for optimum modulation of volumetric ratios at all operating
conditions of the chiller, and have several other advantages.

The Chiller has separate radial and axial force bearings, enhancing the chiller’s life.

Unlike a mono screw compressor, there is no direct contact between the gate
rotor and main rotor, which eliminates wearing out of rotors.

Advanced control algorithm prevents excessive compressor cycling.

It has automatic compressor unloading in case of abnormally high condensing

pressure or discharge temperature and abnormally low suction pressure.

Simulation tools are employed for the design of critical components including
mounting joints, lifting lugs etc.
SIMPLE AND FAST INSTALLATION
The new Blue Star configured series screw chiller is compact and suited for easy and quick
installation. The innovative construction design has the following advantages:

Simple electrical connections including easily accessible main disconnect switch

Victaulic connection aiding in faster and better pipe connections compared to welded
flanged joints

Reversal of chilled water inlet and outlet connections to match site conditions

Systematic factory operation test before shipment

Easy accessibility of all compressor components on site, minimising downtime

Discharge line shut-off valve and liquid line service valve for easy maintenance

Practical reference marks for entering and leaving water connections

Victaulic connections
AHRI CERTIFICATION FOR CHILLERS
The new Blue Star configured series screw chiller is manufactured at
the company’s own state-of-the-art ISO 9001 factory. The chillers are
certifºied by the international rating body - the Air Conditioning, Heating
and Refrigeration Institute (AHRI). Blue Star has India’s only precision
testing facility certified by AHRI to test and rate air cooled chillers
manufactured in the country.
ENVIRONMENT-FRIENDLY
R134a is recognised as an environment-friendly refrigerant which causes no
damage to the ozone layer. The new chiller series with R134a refrigerant is
designed with a leak-tight refrigerant circuit, completely avoiding the capillary
tubes and flare connections with R134a refrigerant.

COMPACT AND LIGHT-WEIGHT

Critical parts, like compressors, coolers and condensers, of these new generation
configured screw chillers are not only efficient but also compact. The chillers are
as much as 15% smaller in size and 10% lesser in weight when compared with a
conventional chiller. The compact design helps to free up valuable floor space.

Width of these chillers are as low as 2.23m and can be easily accommodated in
standard trucks.

MPACT •
• CO

LI T
•

GH
T-W E I G H
 •L
OW
ER NOIS
E•
LOWER NOISE & VIBRATION
The new configured series screw chiller is equipped with 5-lobe, bird-wing
N•
•L

O
W
E R V I B R ATI
O

design fans for optimised noise levels.

Ultra low noise requirement can be catered through

VFD driven condenser fan
Acoustic enclosures for compressors

Specially designed spring isolators provided with the chillers minimise

vibration.
LOW AMBIENT APPLICATION
Applications with high internal loads like data centres need the chillers to
function even during winter conditions.

Condenser fans of the configured series screw chiller are available with the
option of VFD. This will enable to operate the chiller at ambient temperature
as low as 0⁰C.

Operating Range

52
New Blue Star high-efficiency chiller
Conventional chillers
Amb ⁰C

12

0
ANTI-CORROSIVE TREATMENT
Applications involving highly corrosive environments can be provided with
anti-corrosive hydrophobic coated fins, enhancing the corrosion resistance to
more than 5 times the conventional fins.

For more severe applications Blygold metallic impregnated polyurethane

coating can be provided for coils and fins, protecting the base metal from a
wide range of corrosive salts and acids in the atmosphere.

Blygold coating not only protects the chillers from stringent corrosive
environments but also ensures uniform efficiency with negligible impact on
heat transfer and pressure drop.

Blue Fin Blygold

ASME STAMPING
Blue Star’s new generation configured series screw chiller is available with U
Stamp for the pressure vessels in compliance with ASME (American Society
of Mechanical Engineers), a renowned third party certifying organisation for
safety of pressure vessels.
REMOTE MONITORING SYSTEM
The chillers can operate through an advanced GPRS-based Remote Monitoring System
available as an option to all users.

This system has the following advantages:

Close monitoring of the site irrespective

of the location

24x7 i24x7 automatic monitoring

Error signaling
Customer
Service
SERVICE SYSTEM Malfunction
report by
E-mail

Automatic notification in the form of

SMS or e-mail in case of any error

Service Engineer
Automatic call login for service Prompt repairs

The data captured and sent by RMS to the Central Service Team enables analysis by
the local service team to be equipped with the necessary solutions to resolve any issue
speedily. This ensures:

Response time will be very quick

Turnaround time will be faster

Lesser downtime of the system

Option 2
Auto email to RMS Support, who
will analyse in RMS ticketing
system and send email to Blue Star
Customer Support if required

Internet
Chiller RMS Ticketing
Option 1
Auto email to Blue Star RMS Support
RS-485 Network Customer Support Team

RTU

Blue Star Customer

Support Team
Blue Star Customer Support Team
will automatically raise a ticket
in the system and notify the
site service engineer

Service Engineer
Dealers
Customers
ADVANCED FEATURES OF CONTROLLERS

Precise temperature
Overload protection
control of +/- 0.5oC

Anti-freeze and Overcurrent protection

no-flow protection

Compressor run-time HP/LP HP / LP protection

balancing

Automatic backup
Compressor run hours
mode

Single phasing / phase

Password protection
loss protection
 Self-diagnosis
BMS BMS compatibility
control system

User-friendly Stored past history

machine interface and alarm

Alarm output Display unit flexibility

Efficient operating Demand restriction

zone algorithm

Efficient oil separator DLT DLT protection

Oil level protection